Door with variable length screen

ABSTRACT

An exterior door incorporates at least one moving glass insert or sash slidable in first and second spaced apart tracks. An end of the insert is coupled to an end of a spring biased rolled screen. As the insert moves from the roll, the screen is extracted therefrom providing a continuously variable length of exposed screen that exerts a retracting force on the insert. The insert may be supported at any one of a variety of positions by frictional forces exerted on the insert, or by the frictional and retracting forces, without need for counterbalances or latches.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.10/606,039 entitled “Door with Variable Length Screen,” filed Jun. 25,2003, which is a continuation of U.S. patent application Ser. No.10/212,465, now U.S. Pat. No. 6,618,998 entitled “Door with VariableLength Screen,” filed Aug. 5, 2002, which claims the benefit of U.S.Provisional Application No. 60/310,557 filed Aug. 7, 2001.

FIELD OF THE INVENTION

The invention pertains to doors. More particularly, the inventionpertains to doors having at least one slidable glass pane or panel withan extendable screen attached thereto.

BACKGROUND OF THE INVENTION

Storm doors which incorporate panes of glass and screens are known. Someforms of such doors include screens which are fixedly mounted to theframe of the door with sliding glass inserts. With these doors, theinserts usually can be locked into a plurality of vertical positionswith spring loaded latches to expose varying degrees of screen. When theinserts are moved to their fully close position, such as during stormsor in cold weather, a person looking at the door, must look through atleast one pane of glass and the screen.

In other forms of doors, glass inserts or screen inserts are installedon the doors' frame depending on the season. In warmer weather the glassinsert is removed and a screen insert is used in the frame. In coolerweather, the screen is removed and a glass insert is attached to theframe. With such doors, an individual looking at the door looks througheither a pane of glass or a screen but not both.

One known door configuration provides a fixed screen with acounterbalanced insert. In this configuration, the insert is not latchedat a selected position on its track. The counterbalance makes itpossible to position the insert at any desired position o the track.However, when the insert is in its closed position, a person viewing thedoor must look through both the glass insert and the screen.

Patio door configurations are known which include sliding glass doorswhich can be opened or closed to provide access to a patio or a porch.Spring biased screen modules are known which can be attached to thepatio door frame. These modules include horizontally retractable screenswhich can be extended across a patio door opening to exclude insects orother flying pests.

While the known doors are generally suitable for their intended purpose,they all suffer from one or more deficiencies in performance,convenience and ease of use. There continues to be a need formulti-season doors which provide convenient and easy to use screenedopenings during warmer drier weather while at the same time making itpossible to easily close the screened area with a glass pane duringcooler or wetter weather. Preferably such doors could be manufactured,at least in part, using techniques for manufacturing existing doors soas to benefit from the economies of scale that such manufacturingcapabilities provide. Additionally, it would be preferable if such doorswere easy to maintain and designed to be forgiving in the event that thescreen is in need of replacement. Numerous other advantages and featuresof the present invention will become readily apparent from the followingdetailed description of the invention and the embodiments thereof, fromthe claims and from the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a front elevational view of a door in accordance with thepresent invention;

FIG. 1B is a top plan view of the door of FIG. 1A;

FIG. 1C is a side view of the door of FIG. 1A;

FIG. 2A is a rear elevational view of the door of FIG. 1A;

FIG. 2B is a rear elevational view of an alternate door in accordancewith the invention;

FIG. 3A is an exploded view of the door of FIG. 1A;

FIG. 3B is a rear isometric view of the door of FIG. 1A;

FIG. 4A is an exploded view of an alternate embodiment of the door ofFIG. 1A;

FIG. 4B is a rear isometric view of the door of FIG. 4A;

FIGS. 5A and B are side sectional views taken along plane 5A-5A of thedoor of FIG. 1A;

FIG. 5C is a sectional view taken along plane 5C-5C of the door of FIG.1A;

FIG. 5D is an enlargement of a portion of the section of FIG. 5C;

FIG. 5E is a sectional view taken along plane 5E-5E of FIG. 5A;

FIG. 5F is an enlarged partial view of a portion of the door of FIG. 1Aillustrating details thereof;

FIG. 5G is an enlarged partial view illustrating details of an alternateembodiment of the door of FIG. 1A;

FIGS. 6A, 6B and 6C taken together are isometric views illustrating aprocess of engaging an extendable screen cloth with the jambs of thedoor of FIG. 1A;

FIGS. 7A-7C illustrate details of a replaceable screen module usable inthe door of FIG. 1A;

FIG. 8 is a rear isometric view of the door of FIG. 1A illustratingaspects of removing and replacing the screen module;

FIG. 9 is an enlarged region of a portion of FIG. 8 illustratingadditional details thereof;

FIG. 10 is a front elevational view of another door which embodies theinvention;

FIG. 10A is a side section of the door of FIG. 10 taken along plane10A-10A;

FIG. 11 illustrates an end sectional view of a plurality of alternatemechanisms for coupling a retractable screen to a movable door insert;and

FIG. 12 is a rear elevational view of another door in accordance withthe present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

While this invention is susceptible of embodiment in many differentforms, there are shown in the drawing and will be described herein indetail specific embodiments thereof with the understanding that thepresent disclosure is to be considered as an exemplification of theprinciples of the invention and is not intended to limit the inventionto the specific embodiments illustrated.

In one embodiment of the invention, an exterior door incorporates areplaceable screen module which includes an integral, spring biased,retractable screen which is coupled to a movable glass insert in thedoor. As the insert is moved from the screen, the screen is withdrawnfrom its retracted position and extends along the frame of the doorscreening the otherwise open region from which the glass insert hasmoved. As the window sash or insert moves in the opposite directiontoward the screen module, the screen is retracted into the modulereducing the ventilation region available in the door.

FIGS. 1A-1C illustrate various views of a door 10 which embodies thepresent invention. The door 10 includes a header 12 a, two door jambs 12b, c and a sill 12 d. The members 12 a . . . d define a door frame withan interior region which in the door 10 includes a kick plate generallyindicated at 14 a, a lower pane or glass insert 14 b, and an upper paneor glass insert 14 c. Mullions 18 a, b on the exterior side of the framejoin jambs 12 b, c.

In the door 10, the pane or insert 14 b is fixedly mounted between thejambs 12 b, c and above the kick plate 14 a. The pane or insert 14 c ismounted in tracks, discussed in more detail subsequently, for verticalmotion generally in directions 16 a, b relatively to insert 14 b.

When the insert 14 c is positioned at its uppermost location adjacent toheader 12 a, the door 10 is fully closed with two glass panes as onewould use it in cool or wet weather. The pane or insert 14 c can bemoved, vertically, in direction 16 b, away from header 12 a therebyopening the upper portion of door 10 for ventilation.

A screen module 20, best seen in FIG. 7A can be coupled to the jambs 12b, c, header 12 a or sill 12 d. Module 20 carries a retracted screenwhich has a free end which carries an attachment member 22 which iscoupled to an upper end of insert 14 c. As the insert 14 c is moved inthe direction 16 b, screen fabric or material 22-1 from the module 20 isextracted therefrom filling any gap or space between an upper end ofinsert 14 c and header 12 a.

Door 10 can thus, as described above, be converted from a storm doorwith two glass panes to a screen door simply by moving pane or insert 14c vertically downwardly. Where insert 14 c is moved verticallydownwardly to kick plate 14 a, the extracted screen fills the entirearea previously closed by pane 14 c.

When the insert 14 c is raised, direction 16 a, the screen material 22-1retracts into module 20 for storage. As discussed below, module 20 isremovable for maintenance or replacement.

It will be understood that alternate configurations to the door 10 comewithin the spirit and scope of the present invention. For example, thescreen module 20 can be mounted at or near the base 12 d to provide anopenable lower screened region. Alternately, instead of screeningmaterial, sheet plastic could be used in the module 20.

Members 12 a-12 d of the frame for the door 10 can be formed of metal,such as extruded aluminum, extruded or molded plastic, or partly orcompletely of a wood product. Inserts 14 b, c need not include glass butcould in fact be closed with translucent or transparent plastic materialwithout departing from the spirit and scope of the present invention.

FIG. 2A is a rear elevational view of the door 10 illustrating thelocation of screen module 20 adjacent to header 12 a. Screen module 20is enclosed by a removable cover 24 which can be removed for purposes ofmaintenance and for replacing the module 20.

FIG. 2B illustrates an alternate embodiment, a wood core door 10-1 whichincorporates screen module 20. The wood core door 10-1 can be formedwith a wood-products core covered with either metal, such as aluminum,or cured resin such as vinyl. It will be understood that the screenmodule 20 is coupled to a sash or insert, comparable to the insert 14 c,which moves vertically in tracks, as would be understood by those ofskill, in the frame for the door 10-1.

FIGS. 3A and 3B are an exploded view of the door 10 and a rear isometricview thereof.

As illustrated in FIG. 3A, module 20 incorporates a spring or retractorassembly 26 which is carried in a hollow screen roll or cylinder 28. Thecylinder 28 rotates about retractor assembly 26 and pivot cap 28-1.

The module 20 is attached to the door so as to permit rotary motionthereof by brackets 30-1 and 30-2, best seen in FIGS. 7A-C. Screen roll28 carries the coiled screen fabric 22-1 with attached connection member22, best seen in FIG. 7B.

The spring assembly 26 exerts a substantially constant retracting forceon the screen fabric on the roll 28 as the insert 14 c is movedvertically in directions 16 a, b. The screen material 22-1 is thusconstantly under tension.

The insert 14 c in door 10, is counterbalanced by counterbalancingmechanisms 36 a, b carried by the insert 12 a. The counterbalancingmechanisms 36 a, b move with the insert 14 a in the jambs 12 b, c andare invisible to the user. Types of counterbalances include block andtackle balance, spiral balance and coil spring balance.

The counterbalances 36 a, b make it possible to smoothly move the insert14 c in the direction 16 a, b. The insert 14 c can be positionedanywhere along its range of travel and will remain there until moved dueto the forces exerted by the counterbalance mechanisms 36 a, b.

FIGS. 4A, B illustrate an alternate embodiment, a door 10-2, whichembodies the present invention. Those elements of door 10-2 whichcorrespond to previously discussed elements of the door 10 have beenassigned the same identification numerals. As an alternate to thecounterbalance mechanisms 36 a, b, the door 10-2 incorporates springbiased finger operable latches 38 a, b which are carried by the insert14 c′. The latches extend laterally outwardly into slots in the jambs 12b′, c′ to lock the insert 14 c′ into a plurality of spaced apartvertical positions.

In the door 10-2, the insert 14 c′ can be moved vertically to a lockingposition, the movement will retract the screen 22-1 off of the roll 28and filling the area of the door frame from which the insert 14 c′ hasbeen moved. The mechanical latches 38 a, b will lock the insert 14 c′ atthe desired degree of openness in the frame of the door 10-2 desired.

In yet another embodiment, insert 14 c can frictionally engage tracks injambs 12 b, c. The frictional forces will support insert 14 c at any oneof a variety of positions. In this embodiment, no counterbalances orlatches are needed.

FIGS. 5A and 5B are sectional views taken along plane 5A-5A of FIG. 1A.The views of FIGS. 5A, B illustrate the relationship of variousstructural elements of the door 10 as the insert 14 c moves from a fullyclosed position, FIG. 5A, to a partially open position, FIG. 5B. FIG. 5Billustrates the extended screen fabric 22-1.

FIG. 5C, a section taken along plane 5C-5C of FIG. 1A illustrates theinsert tracks 52 b, 52 c which run axially along each of the jambs 12 b,c. The insert 14 c moves axially in and is retained within those tracks.

As illustrated in FIG. 5B, the insert 14 c which is coupled to thescreen fabric 22-1 moves axially in tracks 52 b, c between insert 14 band mullion 18 a. The screen end retaining member 22 is slidablyreceived in a retaining feature 50 located at an upper end of the insert14 c.

Edges of the screen fabric 22-1 are confined in axial tracks 54-1, -2.These can be formed in jambs 12 b, c.

FIG. 5D illustrates the counterbalance mechanism 36 a, b which iscarried by the insert 14 c. Hence, insert 14 c can be located at anyvertical position on its range of travel as defined by the tracks 52 b,52 c along the jambs 12 b, c. When so positioned, the screen fabric22-1, will be extended from the module 20 to the connector feature 50 toclose the opening in the frame of the door 10 left by moving the insert14 c to a position closer to the kick plate 14 a.

FIG. 5D also illustrates the screen material 22-1, illustrated inphantom, extended, as in FIG. 5B, extending between first and secondweather stripping elements 54 a and 54 b. Weather stripping element 54 aextends axially along the respective jamb 12 b, c on each side of thedoor 10. The weather stripping 54 a can be any form of weather strippingas would be known to those of skill in the art.

The weather stripping 54 b is different and unlike the weather stripping54 a. The weather stripping 54 b is also positioned in an axiallyoriented slot which runs along the jambs 12 b, c.

Weather stripping 54 b is commercially available from Reddiplex GroupPLC, Worchestershire, England under the trade name “MESHLOCK” and isformed with a mounting section 56-1 which slidably engages therespective slot in the jamb 12 b, c. The mounting section 56-1 carries adeflectable planar element 56-2 which extends from the mounting section56-1 toward the weather stripping 54 a at a predetermined angle in arange of 15-75° relative to the plane of the screen.

The weather stripping 54 a acts to press the edge of the screen material22-1 toward the MESHLOCK-type weather stripping 54 b, see FIG. 5F. Thisinteraction provides a screen edge retention function. The fibers of theMESHLOCK weather stripping 54 b resist screen material 22-1 being pulledfrom between weather stripping 54 a, b, and the tracks 54-1, -2.

It will be understood that other commercially available forms of weatherstripping can be used instead of the MESHLOCK brand without departingfrom the spirit and scope of the invention.

It will be understood that while the MESHLOCK weather strip 54 b hasbeen illustrated in FIGS. 5D and 5F as exhibiting an acute angle betweenthe mounting section 56-1 and the screen retaining section 56-2, othervariations of MESHLOCK weather stripping could be used. Alternately asin FIG. 5C, the members 56-1′, -2′ could be oriented at 90° to oneanother. In this embodiment, the track in which the mounting section56-1′ would be located would be oriented at an appropriate angle, bestseen in FIG. 5G, relative to the respective jamb 12 b, c to provide thedesired interaction of pressing the screen material 22-1 between theweather stripping 54 a, 54 b′.

FIGS. 6A, B and C taken together illustrate screen fabric or cloth 22-1slidably engaging track 54-1, similarly 54-2, located in each of thejambs 12 b, c and which extend axially along the jamb. The endattachment feature 22 also slidably engages the track or slot 54-1, -2on each of the jambs 12 b, c.

Though the screen cloth or material 22-1 may be forced out of therespective tracks 54-1, -2 in each of jambs by a laterally directedforce, the screen attachment member 22 will continue to remain in eachof the tracks. This is facilitated by the shape of the attachment member22 which includes an end region 23 which extends into the respectiveslot 54-1, -2.

In this instance, assuming that the screen cloth 22-1 has been forcedfrom the respective track 54-1, the upper insert 14 c can be moved toits fully closed position adjacent to header 12 a to retract the screenonto the screen roll 28. In this circumstance, the attachment feature 22is properly aligned to re-enter the tracks 54-1. As the insert 14 c ismoved away from the header 12 a, it will pull the attachment member 22with it. The ends 23 of the attachment member 22 will enter therespective slots 54-1 pulling the screen cloth 22-1 with them andretracking the screen. Alternately, the attachment member 22 can exhibita retracted condition, adjacent to the screen module 20 while continuingto remain in the tracks 54-1.

Thus, as described above, if a force is exerted against the screenmaterial 22-1 to pull it out of the side tracks 54-1 in each jamb, it isonly necessary to reclose the insert 14 c to rewind the screen material22-1 into a proper configuration so that it will be immediatelyre-extendable into the slots or tracks 54-1.

FIGS. 7A, 7B and 7C illustrate additional details of the screen module20. The module 20 is supported adjacent to the header 12 a by brackets30-1, -2. Module 20 can be removably attached to the header, the sill orthe jambs. The module 20 is removable from the brackets 30-1, -2 formaintenance and/or replacement once the cover 24 has been removed fromthe respective door.

FIG. 8 illustrates additional details of removing and replacing themodule 20. The connecting member 22 can be slid from the retainingfeature 50 of the insert 14 c as illustrated in FIGS. 8 and 9. Whenso-slid from the retaining feature 50, the entire module 20 can bereplaced. Replacement involves attaching the connecting member of thenew module to the attachment feature 50 by reversing the processillustrated in FIGS. 8 and 9. The screen roll 28 and screen fabric 22-1can then be reattached brackets such as brackets 30-1, -2 in the headerof the respective door. The cover 24 can be replaced. Moving the insert14 c vertically toward and away from the header will cause the screenfabric 22-1 of the replacement module to retract and extend as expected.

FIGS. 10, 10A and 10B illustrate a door 60 which has a header 62 a,jambs 62 b, c and a sill 62 d. The door 60 includes insert 64 a which ismovable vertically toward the header 62 a and away therefrom toward thesill 62 d. The insert 64 a can be supported by counterbalances, latchesor frictional forces as discussed above relative to the door 10.

The door 60 carries a screen module 66, best illustrated in FIG. 10A. Afree end of the screen of the screen module 66 is coupled to an upperend of insert 64 a as discussed above.

A lower panel 64 b of the door 60 is hollow and contains a space intowhich the insert 64 a can be stored as it is moved downwardly toward thesill 62 d. In this configuration, where the insert 64 a is partly open,a portion of the screen 66 a extends from the screen module 66 and fillsthe open space between jambs 62 b, c and header 62 a. The remainder ofthe space between the jambs 62 b, c is filled by a portion of the insert64 a and the panel 64 b. Thus, the door 60 provides convenient out ofsight storage for the insert 64 a.

FIG. 11 illustrates a plurality of alternate coupling members 50-1 . . .50-6 that could be carried on the movable insert or pane, such as theinsert 14 c, and couplable to a free end of the screen fabric 22-1. Asillustrated in FIG. 11, in each instance, the free end of the screen22-1 would include a coupling element, such as 22-2 . . . 22-7 whichwould slidably engage the respective coupling member 50-1 . . . 50-6.

It will be understood that other arrangements can be used to attach afree end of the screen member 22-1 to a moving insert or pane.Alternates include a spline which would trap the free end of the screenfabric 22-1 in contact with the movable inserts such as 14 c clamps oradhesives. Other variations come within the spirit and scope of theinvention.

FIG. 12 illustrates a door 80 which incorporates a screen module 82, ofthe type discussed previously, which can be attached to door 84 as anafter the fact accessory or add-on. The module screen 82 can be attachedto the door 84 by fasteners 86 in the vicinity of the header 84-1 of thedoor.

The screen fabric 82-1 can be pulled from the module 82 to close anopening in the door created by moving insert 86 downwardly away from themodule 82. A free end 82-2 of the screen material 82-1 is attached tothe sash or insert 86. Attachment can be effected by any of thepreviously discussed methods including using a spline, adhesive,providing attachment clips which slidably engage a portion of the sashof the insert 86. Other attachment vehicles can be used to connect thefree end 82-2 to an upper end of the insert or sash 86 without departingfrom the spirit and scope of the present invention.

As the sash or insert 86 is moved toward the screen module 82, thefabric 82-1 rollably retracts into the module 82 as a result of theinternal spring mechanism, discussed above, in connection with door 10.The screen material 82-1, also as discussed above, is under a constantpulling force due to the spring biasing mechanism of the module 82 whichcontinually attempts to retract the fabric 82-1 into the module 82.Thus, as the sash or insert 86 moves toward the module 82, the screenmaterial 82-1 is immediately rolled into the module 82 for out of theway storage.

It will also be understood that a resin or plastic sheet could be usedas an alternate to screen fabric 82-1 without departing from the spiritand scope of the present invention. Thus, the screen module 82 providesa mechanism for adding to any existing door, after installation, aretractable screen feature such that existing screen panels or insertsin the door can be removed. This improves convenience and visibility inthat with the sash or insert 86 closed, the screen fabric 82-1 iscompletely retracted and an individual looking at the door looksdirectly through the glass inserts or sashes without having to lookthrough a screen.

From the foregoing, it will be observed that numerous variations andmodifications may be effected without departing from the spirit andscope of the invention. It is to be understood that no limitation withrespect to the specific apparatus illustrated herein is intended orshould be inferred. It is, of course, intended to cover by the appendedclaims all such modifications as fall within the scope of the claims.

1. A door comprising: a first door jamb comprising a first track; asecond door jamb comprising a second track; a header portion disposedbetween the first door jamb and the second door jamb; an insert movablewithin the first and second tracks between a first position proximatethe header portion and a second position away from the header portion;and a retractable screen roll proximate the header, the retractablescreen roll including a screen, the screen presenting two side edges anda free end, the free end being operably coupled to the insert, theretractable screen roll applying a retracting force on the screen;wherein a friction force is exerted on the movable insert within thefirst and second tracks such that the insert is supportable at anyposition between the first and second positions.
 2. The door of claim 1,wherein the first track is integral to the first door jamb and thesecond track is integral to the second door jamb.
 3. The door of claim1, wherein at least part of the door is constructed of a materialselected from the group consisting of wood and extruded metal.
 4. Thedoor of claim 1, wherein at least a portion of the friction force isapplied by direct contact between the insert and the first and secondtracks.
 5. The door of claim 1, further comprising a connector thatattaches the free end of the retractable screen roll to the insert, theconnector having ends proximate the side edges of the retractablescreen, the side edges of the retractable screen and the ends of theconnector extending into and being movable within the first and secondtracks.
 6. The door of claim 5, wherein the connector comprises meansfor connecting the free end of the screen to the insert.
 7. The door ofclaim 6, wherein the connector comprises a connector member selectedfrom the group consisting of a spline attachment, an adhesive and aclamp attachment.
 8. A door comprising: a first door jamb comprising afirst track; a second door jamb comprising a second track; a headerportion disposed between the first door jamb and the second door jamb;an insert movable within the first and second tracks between a firstposition proximate the header portion and a second position away fromthe header portion with a force exerted on the insert within the firstand second tracks; and a screen module operably coupled to the door andincluding a retractable screen and a biasing mechanism, the retractablescreen including a free end member operably coupled to the insert andextending into and moveable within the first and second tracks, thebiasing mechanism providing a continuous retracting force on theretractable screen such that the retracting force and the friction forcesupport the insert at any position between the first and secondpositions without the use of a latch.
 9. The door of claim 8, wherein atleast part of the door is constructed of a material selected from thegroup consisting of wood and extruded metal.
 10. The door of claim 8,wherein the screen module is disposed between the first and secondspaced apart jambs proximate the header.
 11. The door of claim 8,wherein the free end member includes a connecting member adapted tooperably connect to the insert.
 12. The door of claim 11, wherein theconnecting member comprises a connector selected from the groupconsisting of a spline connector and a clamp connector.
 13. The door ofclaim 11, wherein the connecting member includes ends that extend intoand are movable within the first and second tracks.
 14. A method ofoperating a door, comprising: providing a door comprising: a first doorjamb including a first track, a second door jamb including a secondtrack, a header portion disposed between the first and second doorjambs, and an insert movable within the first and second tracks betweena first position proximate the header portion and a second position awayfrom the header portion; providing a screen module disposed proximatethe header, the screen module including a retractable screen and abiasing mechanism, the retractable screen including a free end memberoperably coupled to the insert, the free end member extending into andmoveable within the first and second tracks, the biasing mechanismproviding a continuous retracting force on the retractable screen,wherein a friction force is exerted on the insert to support the insertwithin the first and second tracks at any position between the first andsecond positions; and moving the insert to any position between thefirst and second positions.